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At least 181 records · Page 10

IACMI Project 4.10: Blade Finishing Automation (Final Report)

IACMI Project 4.10, the Innovative Wind Turbine Blade Finishing with Advanced Automated Technology project, performed research addressing the challenges and opportunities associated with automating wind turbine blade finishing operations, including blade trimming and grinding. These activities, developed and conducted in close cooperation with wind industry partners, included: • The development of new automation technology and systems; • The integration of automation technology and components; • The improvements of sensor technology and their deployment in automation systems • The elimination of extensive manual programing for the automation of wind blade finishing; • The rethinking of the approach to specific work tasks for automation systems; • The demonstration at scale of innovative wind turbine blade finishing automations systems. The IACMI Wind TA team worked with GE Renewable Energy and LM Wind Power to establish the metrics of the automated blade finishing system developed in the project. In addition, the project team helped to integrate the advanced automated systems into wind turbine blade production facilities. This project was divided into two phases. Phase I provided project management, preliminary techno-economic model development, early US wind turbine industry outreach, and early research into robotic solutions for automated wind blade finishing. This second phase continued with project management, as well as final techno-economic model development, advanced research into robotic solutions for automated wind blade finishing, as well as specifications and procurement of a robotic system for automated wind blade finishing. The 4.10 project leveraged the capabilities and facilities established through the Institute for Advanced Composites Manufacturing Innovation (IACMI), the Colorado Office of Economic Development and International Trade (OEDIT) and the National Renewable Energy Laboratory (NREL). The IACMI Wind Technology Area (TA) designed and prepared for deployment a robotic automated wind turbine blade finishing system at the NREL/IACMI Composites Manufacturing Education and Technology (CoMET) facility. The results of this project led to follow-on funding to build upon and expand research in automated wind turbine blade finishing.

17 WIND ENERGY↗

Thermal Instability in the Manufacturing of Wind Turbine Blade Spar Caps

As wind turbine blades continue to scale in length and total mass, the acceptability of traditional approaches for the engineering of processes to build these products has reached a limit. The continued need to reduce the levelized cost of energy (LCOE) drives manufacturing cycle times lower and the net mass of critical components challenges even the most experienced fabricators to meet the quality requirements for safe operating performance over the 25-year design life of the blade. In trying to reduce cycle time for key components of wind turbines, manufacturers discovered occasional buckling of fibers in wind turbine blade spar caps. The cause of the buckling was unknown. The goal of this project was to show that a comprehensive simulation, which considered all of the physics of the VARTM process, could identify the cause of the fiber buckling in spar caps that has been observed during the manufacturing process. Ultimately, the simulation determined the manufacturing process and parameters could lead to significant compressive stresses in the fibers eventually causing buckling. Simulation results suggest that the stress introduced from friction is the largest source of compressive stress in the fibers, the stress from the weight of gravity is significant but secondary, and the compressive stress from cure shrinkage does not play a significant role in the buckling of fibers. This report provides details of the testing and simulation methodology used to identify the cause of the fiber buckling.

17 WIND ENERGY↗

Investigating lab-scaled offshore wind aerodynamic testing failure and developing solutions for early anomaly detections

As offshore wind systems become more complex, the risk of human error or equipment malfunction increases during experimental testing. This study investigates a lab-scale incident involving a 1 : 50 scale 5 MW wind turbine, where a generator failure led to rotor overspeed and a blade–tower strike. To improve early fault detection, we propose a data-driven method based on multivariate long short-term memory (LSTM) models. High-frequency measurements are projected onto principal components, and anomalies are identified using reconstruction error and its time derivative. Two models are trained on different healthy datasets and tested using single- and multi-principal component (1PC and MPC) variations. Results show that combining both error and error derivative improves detection accuracy. The 1PC model detects faults faster, has a higher recall rate, and achieves a 43 % improvement in anomaly detection accuracy, while the MPC model yields higher precision. This approach provides a simple and effective tool for early anomaly detection in lab-scale experiments, helping to reduce the risk of future failures during the testing of new technologies.

17 WIND ENERGY↗

WIND Toolkit Long-Term Ensemble Dataset

WIND Toolkit Long-term Ensemble Dataset (WTK-LED), an updated version of the meteorological WIND Toolkit, is a meteorological dataset providing high-resolution time series, including interannual variability and model uncertainty of wind speed at every modeling grid point to indicate ranges of possible wind speeds. The data were produced using the Weather Research and Forecasting Model (WRF). The vertical grid used in WTK-LED includes many vertical layers in the atmospheric boundary layer to provide information of atmospheric quantities across the rotor layer of utility scale and distributed wind turbines. The WTK-LED includes: (1) Numerical simulations of wind speed and other meteorological variables covering the contiguous United States (CONUS) and Alaska, with high-resolution (5-minute [min], 2-kilometer [km]) data for 3 years (2018-2020): WTK-LED CONUS, WTK-LED Alaska. (2) Climate simulations from Argonne National Laboratory covering North America, including Alaska, Canada, and most of Mexico and the Caribbean islands. These simulations complement the new WTK-LED to offer a 4-km, hourly dataset covering 20 years (2001-2020): WTK-LED Climate. (3) Specific long-term, high-resolution offshore simulations have been conducted separately for the U.S. coasts, Hawaii, and the Great Lakes, leading to the 2023 National Offshore Wind dataset: NOW-23. The data for Hawaii include land-based data and are part of WTK-LED Hawaii. Because the accuracy of simulations from a mesoscale model, such as WRF, varies depending on the location and weather situation, and can reach up to several m/s for wind speed, we provide simulated wind speed uncertainty estimates to the community to be used in conjunction with the deterministic model simulations. This dataset was developed to satisfy a wide group of stakeholders across various wind energy disciplines, including but not limited to stakeholders in the distributed and utility scale wind industry, the new emerging airborne wind energy field, grid integration, power systems modeling, environmental modeling, and researchers in academia, and to close some of the gaps that current public datasets have. Based on our validation results to date, we suggest use cases and applications for each dataset of the WTK-LED as shown in "WTK-LED Use Cases" resource below.

Array↗

A semi-coupled aero-servo-hydro numerical model for floating vertical axis wind turbines operating on TLPs

Floating vertical axis wind turbines (VAWTs) have many advantages over floating horizontal axis wind turbines (HAWTs) at large scales in deep water; however, there are several key challenges to overcome as well. One of the challenges is accurate prediction of the dynamic motion and loads performance of a floating VAWT. Here, a new semi-coupled aero-servo-hydro method is developed to assess dynamic responses of a floating VAWT by modeling the system as a 7-degree-of-freedom (7-DOF) model: the supporting platform is considered as a 6-DOF rigid body; the rotation of the rotor is considered as the 7th DOF. Aerodynamic, hydrodynamic, and mooring loads and control of the rotor speed are fully considered. This model can predict performance of floating VAWTs with reasonable fidelity according to validation with OrcaFlex through static and dynamic responses of a floating VAWT with Darrieus rotor operating on a new tension-leg platform (TLP). Being a reduced complexity model, the 7-DOF model can be efficiently applied to assess performance of the newly designed floating VAWT. This model is used to examine the relative contributions of aerodynamic and wave loads imparted to the floating system and the benefits of a three-bladed VAWT over a two-bladed VAWT through dynamic and fatigue analysis.

17 WIND ENERGY↗

Turbulence-parameter estimation for current-energy converters using surrogate model optimization

Surrogate models maximize information utility by building predictive models in place of computational or experimentally expensive model runs. Marine hydrokinetic current energy converters require large-domain simulations to estimate array efficiencies and environmental impacts. Meso-scale models typically represent turbines as actuator discs that act as momentum sinks and sources of turbulence and its dissipation. An OpenFOAM model was developed where actuator disc k-ε turbulence was characterized using an approach developed for flows through vegetative canopies. Turbine-wake data from laboratory flume experiments collected at two influent turbulence intensities were used to calibrate parameters in the turbulence-source terms in the k-ε equations. Additionally, parameter influences on longitudinal wake profiles were estimated using Gaussian process regression with subsequent optimization minimizing the objective function within 3.1% of those obtained using the full model representation, but for 74% of the computational cost (far fewer model runs). This framework facilitates more efficient parameterization of the turbulence-source equations using turbine-wake data.

16 TIDAL AND WAVE POWER↗

Simulation of Premixed and Partially Premixed Jet-in-Crossflow Flames at High Pressure

In this paper, we explore the operational map of a lean axial-staged combustor of premixed and partially premixed reacting jet-in-crossflow flames at high -pressure (5 atm). This study attempts to expand the data to relatively high pressure and could significantly aid scaling to real gas turbine engine conditions at 20–30 atm. High-speed camera, particle image velocimetry (PIV), CH* chemiluminescence, temperature, and pressure measurements were taken and processed to allow accurate reconstruction of six operating points relative to computational fluid dynamics (CFD) simulations under minimal adjustments. Variation of lean main stage (φ = 0.575 and 0.73) and rich jet (φ = 1.1, 4, and 8) equivalence ratio has been investigated for a four mm axial jet. The fully premixed flames were found to be controlled by the crossflow temperature before ignition and the crossflow oxygen content during combustion. Analysis of flame shape and position for the partially premixed operating points describes a lee stabilized as well as a more unsteady windward flame branch. Adjustment of added jet fuel and crossflow temperature along with its corresponding oxygen level is required to attain a compact flame body. Here, the risk of delaying combustion progress is significantly increased at a richer jet φ = 8 and an overshooting, spatially divided flame was attained with a main stage φ = 0.73. Control toward a compact flame body is critical to allow combustion at reasonable reaction rate.

03 NATURAL GAS↗

Bias Characterization, Vertical Interpolation, and Horizontal Interpolation for Distributed Wind Siting Using Mesoscale Wind Resource Estimates

Much like their counterparts in utility-scale wind energy, developers of industrial, small-scale and distributed wind turbine deployments need to understand and accurately characterize the wind resource to properly assess the power generation and financial ramifications during siting and planning. National Renewable Energy Laboratory’s WIND (Wind Integration National Dataset) Toolkit (WTK) provides a best-in-class wind resource dataset generated using the Weather Research and Forecasting (WRF) model. This dataset includes parameters such as the wind speed, wind direction, and temperature at various heights, plus atmospheric stability near the surface. This data is available at 2-km spatial resolution and five-minute temporal resolution across 7 years, from 2007 to 2013 through a publicly accessible API interface. The Tools Assessing Performance (TAP) project seeks to extend this dataset to allow long term resource estimates and leverage it to better equip distributed wind equipment manufacturers, owner-operators, and installation professionals with better tools for practical siting applications. In this report, we present the results from our investigation within the TAP project focused on characterization of bias in WTK-based wind speed estimates and evaluation of vertical and horizontal interpolation techniques. We discuss the tradeoffs between different techniques and their combinations, as well as describe the lower bounds we determine for the studied validation errors. While the specific estimates we present are specific to WTK and the validation dataset we have chosen for this investigation (NREL's Wind Resource Meteorological Database), the overall analysis and the studied techniques are general enough to be applied to a broader set of wind datasets, both simulation-based and observational.

17 WIND ENERGY↗

WTK-LED: The WIND Toolkit Long-Term Ensemble Dataset

To satisfy a wide group of stakeholders across various wind energy disciplines, including but not limited to stakeholders in the distributed and utility scale wind industry, the new emerging airborne wind energy field, grid integration, power systems modeling, environmental modeling, and researchers in academia, and to close some of the gaps that current public datasets have, we aimed at developing an updated version of the meteorological WIND Toolkit, named WIND Toolkit Long-term Ensemble Dataset (WTK-LED), which is a meteorological dataset providing time series every 5 min and 2 km, including model uncertainty of wind speed at every modeling grid point so that users are provided with a range of possible wind speeds every 2 km. The data were produced using the Weather Research and Forecasting Model (WRF). The vertical grid used in WTK-LED includes many vertical layers in the atmospheric boundary layer to provide information of atmospheric quantities across the rotor layer of utility scale and distributed wind turbines. The WTK-LED includes: 1) Numerical simulations covering the continental United States, Alaska, and Hawaii, with high-resolution data being available for 3 years (2018-2020). 2) Climate simulations from Argonne National Laboratories covering the North American continent, including Alaska, Canada, and most of Mexico and the Caribbean Islands. These simulations complement the new WTK-LED to offer a 4-km dataset covering 20 years, from 2001-2020. 3) Specific long-term,high-resolution offshore simulations have been conducted separately for the US coasts, Hawaii, and the Great Lakes, leading to the 2023 National Offshore Wind data set. This report focuses on a description of the land-based WTK-LED for CONUS, Hawaii, and Alaska, for the 3-year 2-km/5-min dataset and the 20-year 4-km/hourly dataset, as well as the uncertainty quantification method. We also provide limited validation results. Based on our results to date, we suggest use cases and applications for each dataset of the WTK-LED.

17 WIND ENERGY↗

Development of a Large-Scale Open Geometry for Squealer Tip Coolant Injection Research

In this work, a large-scale symmetric canonical axial turbine squealer tip model is developed, which allows for the investigation of incoming gas path flow interaction with coolant flow injected into the squealer cavity. The model is developed to investigate Reynolds numbers on the order of one million for their applicability to novel supercritical CO2 cycles.

Tuite, Logan M.↗

New insights on wind turbine wakes from large‐eddy simulation: Wake contraction, dual nature, and temperature effects

Abstract Large‐eddy simulation (LES) has been adopted to study wind turbine wakes because it can capture fine‐scale details of turbulent wind flows and interactions with wind turbines. Here, we use the LES version of the Weather Research and Forecasting (WRF) model with an actuator disk model to gain insights on several wake effects that have been traditionally difficult to measure. The first finding is that the wake has a “dual nature,” meaning that the wind speed deficit behaves differently from the added turbulent kinetic energy (TKE) and the two are not co‐located in space. For example, the wind speed deficit peaks at hub height and reaches the ground within 8D (D is the rotor diameter), but added TKE peaks near the rotor tip and generally remains aloft. Second, temperature changes near the ground are driven by the added TKE in the rotor area and by atmospheric stability. The combination of these two factors determines the sign and intensity of the vertical heat flux divergence below the rotor, with convergence and warming associated with stable conditions and weak divergence and modest cooling with unstable conditions. Third, wakes do not expand indefinitely, as suggested by similarity theory applied to the wind speed deficit, but eventually stop expanding and actually contract, at different rates depending on atmospheric stability. The implication of these findings is that, in order to study wakes, it is not sufficient to focus on wind speed deficit alone, because TKE is also important and yet behaves differently from the wind speed deficit.

17 WIND ENERGY↗

Robust wind farm layout optimization

Wake interactions in wind farms cause losses in annual energy production (AEP) on the order of 10%. Wind farm designers optimize the layout of the farm to mitigate wake losses, especially in the dominant site-specific wind directions. As wind turbines and wind farms grow in scale, optimization becomes more complex. Offshore wind farms regularly comprise more than 100 wind turbines and are characterized by complex boundaries due to shipping lanes, neighboring wind farms, and other constraints. Layout optimization methods are broadly split between gradient-based and gradient-free approaches. Gradient-based approaches can converge quickly and perform well for smaller, academic problems but are often sensitive to initial conditions and tuning parameters and require expert knowledge to use. On the other hand, gradient-free approaches can be more robust to problem complexities. We present a robust layout optimization approach based on a random search algorithm. The algorithm is intended for those who are not optimization experts and has few tuning parameters that need specification to achieve satisfactory results. Unlike off-the-shelf methods, which use generally available, non-domain-specific optimization routines that accept as inputs an optimization function and constraint definitions, this approach takes advantage of the relative computational costs of the different evaluations by evaluating cheaper computations first (boundary and minimum distance constraints) and running expensive AEP evaluations only if all other checks pass. Moreover, an outer genetic algorithm allows multiple solutions to evolve in parallel, enabling rapid solution development on high-performance computers. We discuss the relative ease of selecting necessary tuning parameters and demonstrate the efficacy of the genetic random search on a complex layout problem consisting of placing 70 turbines in a nonconvex and unconnected boundary region.

17 WIND ENERGY↗

Floating platform effects on power generation in spar and semisubmersible wind turbines

The design and financing of commercial-scale floating offshore wind projects require a better understanding of how power generation differs between newer floating turbines and well-established fixed-bottom turbines. In floating turbines, platform mobility causes additional rotor motion that can change the time-averaged power generation. In this work, OpenFAST simulations examine the power generated by the National Renewable Energy Laboratory's 5-MW reference turbine mounted on the OC3-UMaine spar and OC4-DeepCWind semisubmersible floating platforms, subjected to extreme irregular waves and below-rated turbulent inflow wind from large-eddy simulations of a neutral atmospheric boundary layer. For these below-rated conditions, average power generation in floating turbines is most affected by two types of turbine displacements: an average rotor pitch angle that reduces power, caused by platform pitch; and rotor motion upwind-downwind that increases power, caused by platform surge and pitch. The relative balance between these two effects determines whether a floating platform causes power gains or losses compared to a fixed-bottom turbine; for example, the spar creates modest (3.1%–4.5%) power gains, whereas the semisubmersible creates insignificant (0.1%–0.2%) power gains for the simulated conditions. Furthermore, platform surge and pitch motions must be analyzed concurrently to fully capture power generation in floating turbines, which is not yet universal practice. Finally, a simple analytical model for predicting average power in floating turbines under below-rated wind speeds is proposed, incorporating effects from both the time-averaged pitch displacement and the dynamic upwind-downwind displacements.

17 WIND ENERGY↗

Liquid Air Combined Cycle TM for Power and Storage

Liquid Air Combined Cycle (LACC) is a hybrid liquid air energy storage (LAES) system combining energy storage with a combustion turbine to enable large-scale, long-duration energy storage (LDES) while reducing fuel intensity compared to the current state-of-the-art. The LACC technical approach employs proven equipment (cryogenic refrigeration, storage, tanks, pumps, gas turbines, exhaust heat recovery equipment, and turbines) to limit technical risk to a novel organic Rankine cycle (ORC), which was evaluated during this project and found to be feasible. Moreover, LACC storage is safe and relatively compact, to facilitate siting close to loads and within metropolitan regions. The air storage medium is freely available and eliminates supply chain constraints. LACC uses cryogenic air as a storage medium and a gas turbine as the source of heat to drive the discharge process. LACC is distinguished from other LAES technologies by several factors. The charge and discharge processes are decoupled so that cryogenic liquid air is the only storage medium. Other systems also store the higher temperature thermal energy from the liquefaction process in an additional medium. Subsequently, LACC focuses on maximization of the discharge energy and power. LACC also permits the use of commercially available cryogenic refrigeration and storage technologies to increase competition. This project identified product requirements to support market entry and commercialization of the LACC in modular units of approximately 117 MW, each drawing liquid air from customary cryogenic storage tanks capable of storing 75 GWh of dispatchable energy, more than pumped storage hydro or compressed air energy storage technologies. An economic analysis identified the specific liquid air consumption (quantity of liquid air per unit of discharge energy) as a critical parameter. Minimizing the air consumption reduces the specific capital cost ($\$ $/kW) for charging and discharging equipment by reducing the size of piping and turbomachinery. Likewise, the specific cost of energy capacity ($\$ $/kWh) is reduced by increasing the energy deliverable from a given size tank. The cycle was analyzed to identify the optimal equipment selection and operating conditions, which in turn were combined with quotes and cost estimates to calculate the cost of energy from an LACC system. A substantial effort was focused on the ORC, which draws low-temperature heat from the gas turbine exhaust and condenses at low temperature using the cryogenic liquid air as a heat sink. Alternative turbomachinery arrangements were evaluated for feasibility and cost. A technology maturation plan lays out a low-risk approach to development of the novel ORC components and demonstration of LACC technology at pilot scale.

25 ENERGY STORAGE↗

JHTDB-wind: a web-accessible large-eddy simulation database of a wind farm with virtual sensor querying

This paper introduces JHTDB-wind (https://turbulence.idies.jhu.edu/datasets/windfarms, last access: 11 November 2025), a publicly accessible database containing large-eddy simulation (LES) data from wind farms. Building on the framework of the Johns Hopkins Turbulence Database (JHTDB), which hosts direct numerical simulation (DNS) and some LES datasets of canonical turbulent flows, JHTDB-wind stores the 4D space–time history of the flow and provides users the ability to access and query the data via a web-based virtual sensor interface. The initial dataset comprises LES results from a large wind farm with 10×6 turbines, modeled using a filtered actuator line method, under conventionally neutral atmospheric conditions. These data comprise 1 h (hour) of flow field data (velocity, pressure, potential temperature deviation, subgrid-scale (SGS) eddy viscosity, and turbine forces, approximately 15 TB (terabytes) and wind turbine data – including both turbine-level operational quantities and blade-level aerodynamic quantities (approximately 1.3 TB) – stored in Zarr and Parquet formats, respectively. Data retrieval is facilitated by the giverny Python package, allowing remote users to query the database in Python or MATLAB (C and Fortran support are available for flow field data). This paper details the simulation setup and demonstrates data access through examples that analyze wind farm flow structures and turbine performance. The framework is extensible to future datasets, including the JHTDB-wind diurnal cycle simulation analyzed in Xiao et al. (2025).

17 WIND ENERGY↗

Site Selection for Field Testing of a Marine Hydrokinetic Turbine Platform to Serve as a Floating Unmanned Mobile Recharging Station for Aerial Drones

Abstract Expanding applications of unmanned aerial vehicles (UAVs) in coastal areas suggests a need for stations along or close to the coast where the UAV batteries can be easily recharged. A small-scale low flow marine current turbine in support of a floating autonomous recharge station for small UAVs has been designed and assembled at Florida Atlantic University and is being prepared for field testing. Surveys of identified test sites in the Intracoastal Waterways and at open ocean locations are being conducted to determine their suitability in meeting resource, system design and permitting requirements. A sensor platform has been developed for measuring local currents at the identified sites in support of resource characterization. Two out of the eight sites surveyed in the Intracoastal Waterways are found to meet the field-testing requirements for current resource, water depth, and sea bottom conditions. Planned field testing will include parametric characterization studies of the performance of the current turbine for a range of turbine blade configurations, current speeds, turbine wheel submergence levels, and test site location (channeled flow vs open ocean flow).

McKinney, Adriana Lynell↗

Characterizing Flow Instabilities During Transient Events in the Turbine Rim Seal Cavity

Abstract Gas turbine engine design requires considerations not only for long-term steady operation but also for critical transient events. Aircraft engines undergo significant stress during takeoff and landing, while power generation turbines must be flexible for hot restarts as renewable energy sources come online and offline. During these transient cycles, engines sustain wear and degradation that can lead to a reduction in the lifespan of their components and more frequent, costly maintenance. Cooling flows are often used to mitigate these effects, but can lead to complex and problematic flow interactions. This study uses high-frequency response pressure probes and heat flux gauges in the rim seal cavity of a one-stage research turbine to characterize the properties of large-scale flow structures during transient operation. A continuous-duration turbine testing facility provides the ability to assess the importance of these transients by first reaching steady-state operation before imposing transient behaviors. Although previous studies have conducted similar measurements for steady purge flows and wheel speeds, varying these parameters to simulate transient effects revealed several unique phenomena not identifiable with discrete steady measurements. The measurement approach connects the varied transient parameter to the behavior of the flow structures to enable a better understanding of the type of instability observed and the root cause of its formation. In particular, a relationship between instability cell formation and rim sealing effectiveness was identified using experimental data and was supported through computational simulations.

Engineering↗

Do ambient shear and thermal stratification impact wind turbine tip-vortex breakdown?

Modern wind turbines experience uneven inflow conditions across the rotor, due to the ambient flow’s shear and thermal stratification. Such conditions alter the shape and length of turbine wakes and thus impact the loads and power generation of downstream turbines. To this end, understanding the spatial evolution of the individual wakes under different atmospheric conditions is key to controlling and optimising turbine arrays. With this numerical study we aim to obtain a better understanding of the fundamental physics governing the near-wake dynamics of wind turbines under shear and thermal stability, by examining their tip-vortex breakup mechanisms. Our approach considers scale-resolving simulations of a single turbine wake under a linear shear profile as well as the application of harmonic tip perturbations to trigger flow instabilities. For the subsequent analysis we use the proper orthogonal decomposition (POD) method to extract coherent structures from the flow, and we also calculate mean kinetic energy fluxes to quantify each coherent structure’s contribution to wake recovery. The wake’s helical spiral is found to hinder wake recovery for all studied ambient flow conditions, whereas the mutual inductance instability has positive MKE flux leading to an enhanced wake recovery. Finally, the ambient shear has the largest impact on the local MKE flux with respect to downstream location by changing the shape of the curve and location of extrema, whereas thermal stratification has only a minimal impact on the magnitude of the near-wake local MKE flux distribution.

17 WIND ENERGY↗